System and method for inspection of roll surface

ABSTRACT

A system and method that includes, in an embodiment, a prism, a camera, a light source, and a plate. The system, in an embodiment, is configured for scanning a roll and generating an image of the roll surface. The prism, in an embodiment, is positioned below the camera and above the plate. In an embodiment, the plate is positioned below the prism and above the roll surface. In an embodiment, the light source is positioned above the prism. In an embodiment, the light source and the prism are positioned to provide light to the roll surface at an angle of at least 75 degrees measured from a line normal to the roll surface. In an embodiment, the prism is configured to refract light from the light source, the camera is a line scan camera that includes a row of pixel sensors, and the light source includes light emitting diodes.

RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/208,900, entitled “SYSTEM AND METHOD FOR INSPECTION OF ROLL SURFACE”,filed Mar. 13, 2014, which claims the benefit of U.S. ProvisionalApplication No. 61/780,270, entitled “SYSTEM AND METHOD FOR WETINSPECTION OF ROLL SURFACE,” filed Mar. 13, 2014, which are herebyincorporated by reference herein in their entirety for all purposes.

TECHNICAL FIELD

The system and method relate to inspection of a roll used for hot orcold rolling metal.

BACKGROUND

Methods for inspecting roll surfaces are known.

SUMMARY OF INVENTION

In some embodiments, the system includes: (i) a prism, (ii) a camera,(iii) a light source, and (iv) a plate. In some embodiments, the systemis configured for scanning a roll and generating an image of a surfaceof the roll. In some embodiments, the prism is positioned below thecamera and above the plate. In some embodiments, the plate is positionedbelow the prism and on or above the surface of the roll.

In some embodiments, the light source is positioned above the prism. Insome embodiments, the light source and the prism are positioned toprovide light to the surface of the roll at an angle of at least 75degrees as measured from a line normal to the surface of the roll. Insome embodiments, the prism is configured to refract light from thelight source. In some embodiments, the camera is a line scan camera thatincludes at least one row of pixel sensors. In some embodiments, thelight source includes one or more light emitting diodes.

In some embodiments, the plate is positioned between 0.005 inches and0.05 inches from the roll. In some embodiments, the plate is positionedbetween 0.005 and 0.020 inches from the roll. In some embodiments, theplate is positioned 0.005 inches from the roll.

In some embodiments, the coolant is positioned between the plate and theroll. In some embodiments, the plate comprises a polymeric material. Insome embodiments, the light source and the prism are positioned toprovide light at an angle of 78 degrees as measured from the line normalto the surface of the roll.

In some embodiments, the method includes lighting a surface of a rollusing a light source and a prism. In some embodiments, the light sourceand the prism are positioned to provide light to the surface of the rollat an angle of at least 75 degrees as measured from a line normal to thesurface of the roll. In some embodiments, the method further includesreceiving, by at least one specifically programmed computer system, aplurality of lines from a line scan camera while the roll is rotating.In some embodiments, each line corresponds to a section of the roll.

In some embodiments, the method includes creating, by the at least onespecifically programmed computer system, a plurality of frames based, atleast in part, on the plurality of lines. In some embodiments, themethod includes generating, by the at least one specifically programmedcomputer system, the two-dimensional image of the surface of the rollbased, at least in part, on the plurality of frames.

In some embodiments, the plurality of lines is received at a speed of1000 to 5000 lines per second. In some embodiments, each of theplurality of frames is formed of at least 1000 lines. In someembodiments, the surface of the roll is at least partially covered by afluid during the receiving step. In some embodiments, the line scancamera moves in a transverse direction relative to the roll during thereceiving step.

In some embodiments, a first speed of the rotating roll is greater thana second speed of the moving line scan camera. In some embodiments, thefirst resolution of the image in the transverse direction is less than asecond resolution of the image in a circumferential direction.

In some embodiments, the method includes lighting a surface of a rollusing a light source and a prism. In some embodiments, the light sourceand the prism are positioned to provide light to the surface of the rollat an angle of at least 75 degrees as measured from a line normal to thesurface of the roll. In some embodiments, the method includes receiving,by at least one specifically programmed computer system, a plurality oflines from a line scan camera while the roll is rotating. In someembodiments, each line corresponds to a section of the roll.

In some embodiments, the method includes creating, by the at least onespecifically programmed computer system, a plurality of frames based, atleast in part, on the plurality of lines. In some embodiments, themethod includes generating, by the at least one specifically programmedcomputer system, the two-dimensional image of the surface of the rollbased, at least in part, on the plurality of frames. In someembodiments, the method includes evaluating, by the at least onespecifically programmed computer system, defects on the roll based, atleast in part, on the two-dimensional image of the surface of the roll.In some embodiments, the method includes grinding the roll based, atleast in part, on the evaluation of the defects on the roll.

In some embodiments, the evaluating step and the generating step areconducted concomitantly. In some embodiments, the evaluating step andthe grinding step are conducted concomitantly. In some embodiments, thesurface of the roll is at least partially covered by a fluid during thereceiving step. In some embodiments, the line scan camera moves in atransverse direction relative to the roll during the receiving step.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further explained with reference to theattached drawings, wherein like structures are referred to by likenumerals throughout the several views. The drawings shown are notnecessarily to scale, with emphasis instead generally being placed uponillustrating the principles of the present invention. Further, somefeatures may be exaggerated to show details of particular components.

FIG. 1 illustrates features of some embodiments of the presentinvention.

FIG. 2 illustrates features of some embodiments of the presentinvention.

FIG. 3 illustrates features of some embodiments of the presentinvention.

FIG. 4 illustrates features of some embodiments of the presentinvention.

FIG. 5 illustrates features of some embodiments of the presentinvention.

FIG. 6 illustrates features of some embodiments of the presentinvention.

FIG. 5 illustrates features of some embodiments of the presentinvention.

FIGS. 7A-7D illustrate features of some embodiments of the presentinvention.

FIGS. 8A-8C illustrate features of some embodiments of the presentinvention.

FIG. 9 illustrates a frame created by an embodiment of the method of thepresent invention.

FIG. 10 illustrates an image created by an embodiment of the method ofthe present invention.

FIG. 11 illustrates features of some embodiments of the presentinvention.

FIG. 12 illustrates features of some embodiments of the presentinvention.

The figures constitute a part of this specification and includeillustrative embodiments of the present invention and illustrate variousobjects and features thereof. Further, the figures are not necessarilyto scale, some to features may be exaggerated show details of particularcomponents. In addition, any measurements, specifications and the likeshown in the figures are intended to be illustrative, and notrestrictive. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

DETAILED DESCRIPTION

The present invention will be further explained with reference to theattached drawings, wherein like structures are referred to by likenumerals throughout the several views. The drawings shown are notnecessarily to scale, with emphasis instead generally being placed uponillustrating the principles of the present invention. Further, somefeatures may be exaggerated to show details of particular components.

The figures constitute a part of this specification and includeillustrative embodiments of the present invention and illustrate variousobjects and features thereof. Further, the figures are not necessarilyto scale, some features may be exaggerated to show details of particularcomponents. In addition, any measurements, specifications and the likeshown in the figures are intended to be illustrative, and notrestrictive. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

Among those benefits and improvements that have been disclosed, otherobjects and advantages of this invention will become apparent from thefollowing description taken in conjunction with the accompanyingfigures. Detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely illustrative of the invention that may be embodied in variousforms. In addition, each of the examples given in connection with thevarious embodiments of the invention which are intended to beillustrative, and not restrictive.

Throughout the specification and claims, the following terms take themeanings explicitly associated herein, unless the context clearlydictates otherwise. The phrases “in one embodiment” and “in someembodiments” as used herein do not necessarily refer to the sameembodiment(s), though it may. Furthermore, the phrases “in anotherembodiment” and “in some other embodiments” as used herein do notnecessarily refer to a different embodiment, although it may. Thus, asdescribed below, various embodiments of the invention may be readilycombined, without departing from the scope or spirit of the invention.

In addition, as used herein, the term “or” is an inclusive “or”operator, and is equivalent to the term “and/or,” unless the contextclearly dictates otherwise. The term “based on” is not exclusive andallows for being based on additional factors not described, unless thecontext clearly dictates otherwise. In addition, throughout thespecification, the meaning of “a,” “an,” and “the” include pluralreferences. The meaning of “in” includes “in” and “on.”

In some embodiments, the system includes: (i) a prism, (ii) a camera,(iii) a light source, and (iv) a plate. In some embodiments, the systemis configured for scanning a roll and generating an image of a surfaceof the roll. In some embodiments, the prism is positioned below thecamera and above the plate. In some embodiments, the plate is positionedbelow the prism and on or above the surface of the roll.

In some embodiments, the light source is positioned above the prism. Insome embodiments, the light source and the prism are positioned toprovide light to the surface of the roll at an angle of at least 75degrees as measured from a line normal to the surface of the roll. Insome embodiments, the prism is configured to refract light from thelight source. In some embodiments, the camera is a line scan camera thatincludes at least one row of pixel sensors. In some embodiments, thelight source includes one or more light emitting diodes.

In some embodiments, the plate is positioned between 0.005 inches and0.05 inches from the roll. In some embodiments, the plate is positionedbetween 0.005 and 0.020 inches from the roll. In some embodiments, theplate is positioned 0.005 inches from the roll.

In some embodiments, the coolant is positioned between the plate and theroll. In some embodiments, the plate comprises a polymeric material. Insome embodiments, the light source and the prism are positioned toprovide light at an angle of 78 degrees as measured from the line normalto the surface of the roll.

In some embodiments, the method includes lighting a surface of a rollusing a light source and a prism. In some embodiments, the light sourceand the prism are positioned to provide light to the surface of the rollat an angle of at least 75 degrees as measured from a line normal to thesurface of the roll. In some embodiments, the method further includesreceiving, by at least one specifically programmed computer system, aplurality of lines from a line scan camera while the roll is rotating.In some embodiments, each line corresponds to a section of the roll.

In some embodiments, the method includes creating, by the at least onespecifically programmed computer system, a plurality of frames based, atleast in part, on the plurality of lines. In some embodiments, themethod includes generating, by the at least one specifically programmedcomputer system, the two-dimensional image of the surface of the rollbased, at least in part, on the plurality of frames.

In some embodiments, the plurality of lines is received at a speed of1000 to 5000 lines per second. In some embodiments, each of theplurality of frames is formed of at least 1000 lines. In someembodiments, the surface of the roll is at least partially covered by afluid during the receiving step. In some embodiments, the line scancamera moves in a transverse direction relative to the roll during thereceiving step.

In some embodiments, a first speed of the rotating roll is greater thana second speed of the moving line scan camera. In some embodiments, thefirst resolution of the image in the transverse direction is less than asecond resolution of the image in a circumferential direction.

In some embodiments, the method includes lighting a surface of a rollusing a light source and a prism. In some embodiments, the light sourceand the prism are positioned to provide light to the surface of the rollat an angle of at least 75 degrees as measured from a line normal to thesurface of the roll. In some embodiments, the method includes receiving,by at least one specifically programmed computer system, a plurality oflines from a line scan camera while the roll is rotating. In someembodiments, each line corresponds to a section of the roll.

In some embodiments, the method includes creating, by the at least onespecifically programmed computer system, a plurality of frames based, atleast in part, on the plurality of lines. In some embodiments, themethod includes generating, by the at least one specifically programmedcomputer system, the two-dimensional image of the surface of the rollbased, at least in part, on the plurality of frames. In someembodiments, the method includes evaluating, by the at least onespecifically programmed computer system, defects on the roll based, atleast in part, on the two-dimensional image of the surface of the roll.In some embodiments, the method includes grinding the roll based, atleast in part, on the evaluation of the defects on the roll.

In some embodiments, the evaluating step and the generating step areconducted concomitantly. In some embodiments, the evaluating step andthe grinding step are conducted concomitantly. In some embodiments, thesurface of the roll is at least partially covered by a fluid during thereceiving step. In some embodiments, the line scan camera moves in atransverse direction relative to the roll during the receiving step.

Traditional mills may include a metal forming process called rolling.Rolling includes passing metal including, but not limited to, aluminum,through a pair of rolls. Depending on the temperature, rolling may beclassified as “hot” rolling or “cold” rolling.

The rolling process typically results in defects in the surface of eachroll. For example, metal may adhere to the roll during the rollingprocess. These defects in the surface of each roll affect the quality ofthe rolled product and thus require removal.

Typically, the defects on the surface of the roll are removed using agrinding process or equivalent. The grinding process may includecontacting the surface of the roll with a grinding wheel to remove thedefects. To prevent heat buildup and wash away grinding debris, thegrinding process also typically includes a coolant directed towards thewheel and roll contact. This coolant includes, but is not limited to, awater-based coolant, prior to or concurrent with grinding.

In some embodiments, the present invention includes a method and systemfor wet inspection of the roll surface during grinding. In someembodiments, the system includes a roll, a prism, a camera, a lightsource, and a plate; wherein the prism is positioned between the cameraand the roll and configured to refract light from the light source;wherein the camera includes one row of pixel sensors; wherein the lightsource includes one or more light emitting diodes; wherein the one ormore light emitting diodes are configured to provide light at an anglegreater than or equal to 75 degrees as measured from a line normal to asurface of the roll; wherein the plate is positioned between the cameraand the surface of the roll and located greater than 0.005 inches andless than 0.05 inches from the roll.

In some embodiments, the system includes a camera 100 (200, 300, 400,500, 600) with lens 105 (405, 605), a prism 110 (310, 510, 610), a lightsource 120 (220, 320, 420, 620), a plate 130 (230, 330, 430, 530) and aroll 140 (240, 440, 540, 640) as shown in FIGS. 1-6. In someembodiments, the plate 130 includes one or more apertures 160 (360).

In some embodiments, FIG. 1 also shows a non-limiting example of agrinding wheel 150. In some embodiments, the grinding wheel is 36″diameter. In some embodiments, the grinding wheel is 24″ diameter. Insome embodiments, the grinding wheel is 48″ diameter. In someembodiments, the grinding wheel is greater than 48″ diameter. In someembodiments, the grinding wheel is less than 24″ diameter. In someembodiments, the grinding wheel is 56″ diameter. In some embodiments,the grinding wheel is 60″ diameter.

FIGS. 2-6 show multiple embodiments of the system of the presentinvention. FIG. 2 shows an embodiment that includes a light source 220comprising multiple light emitting diodes. FIG. 4 also shows anembodiment where the light contacts the surface of the roll 440 at anangle 490 (690) of 78 degrees from a line normal to the roll. FIG. 4also shows an embodiment where the light contacts the surface of theroll at an angle 495 (695) of 45 degrees from a line normal to the roll.FIG. 4 also illustrate additional components of an embodiment of asystem of the present invention such as a gap control sensor 470 (570).FIG. 5 illustrates a coolant delivery device such as a hose 580 of anembodiment of the present invention.

FIG. 6 shows the light path 625 of light emitted from a light source 620in an embodiment of the present invention. FIG. 6 also shows a field ofview 608 of the camera of an embodiment of the present invention.

In some embodiments, the camera is a line scan camera. In someembodiments, the camera is a digital camera that includes a sensor witha single line of light sensing pixels. In some embodiments, the cameraprovides different pixel resolution in the transverse andcircumferential directions relative to the roll and thus reduces theamount of image data requiring subsequent processing. In someembodiments, the line of pixels associated with the line scan camera isaligned along a long axis of the roll. In some embodiments, the camerauses the line of pixels to continuously scan the roll and thus generatean image of the roll surface. In some embodiments, the line scan camerais a Dalsa Technology Piranha2 Model P2-2x-xxx40.

In some embodiments, the prism refracts the light from the light sourceto correct the distortion of light associated with i) the wetted roll,ii) coolant positioned between the roll and/or iii) the plate positionedbetween the prism and the coolant. In some embodiments, the angles ofthe facets of the prism are configured to correct the refraction oflight from air, the plate material, and/or coolant. In some embodiments,the prism is positioned such that the light from the light sourcetravels through one or more flat surfaces or faces of the prism. In someembodiments, the prism is positioned such that the light from the lightsource travels through one or more edges of the prism. In someembodiments, each edge of the prism is formed when the flat surfaces orfaces of the prism intersect. In some embodiments, the prism ispositioned a sufficient distance from the roll surface so as to resultin protection of the prism from debris from the grinding process.

In some embodiments, the distance between the prism and roll surface is0.03 inches to 0.7 inches. In some embodiments, the distance between theprism and roll surface is 0.03 inches to 0.5 inches. In someembodiments, the distance between the prism and roll surface is 0.03inches to 0.3 inches. In some embodiments, the distance between theprism and roll surface is 0.03 inches to 0.1 inches. In someembodiments, the distance between the prism and roll surface is 0.1inches to 0.7 inches. In some embodiments, the distance between theprism and roll surface is 0.3 inches to 0.7 inches. In some embodiments,the distance between the prism and roll surface is 0.5 inches to 0.7inches.

In some embodiments, the prism is formed of a material capable ofrefracting light. In some embodiments, the prism is formed of acrylic orother polymeric material. In some embodiments, the prism is formed ofglass. In some embodiments, the prism is translucent. In someembodiments, the prism is polished so as to be optically clear andsubstantially free of any scratches or visible defects. FIGS. 7A and 7Bare top and bottom views, respectively, of a non-limiting example of theprism of the present invention. FIG. 7C is a front view of anon-limiting example of the prism of the present invention. FIG. 7D is across-sectional view of a non-limiting example of the prism of thepresent invention.

In some embodiments, the light source includes one or more lights forillumination of the mill roll. In some embodiment the lights mayinclude, but are not limited to, incandescent lamps, lasers, lightemitting diodes, and/or other light source sufficient for illuminatingthe mill roll. In some embodiments, the one or more lights is positionedat an angle of greater than 45 degrees and less than 90 degrees asmeasured from a line normal to the rolling surface. In some embodiments,the one or more lights is positioned at an angle of greater than 60degrees and less than 90 degrees from normal as measured from a linenormal to the roll surface. In some embodiments, the one or more lightsis positioned at an angle of greater than 70 degrees and less than 90degrees from normal as measured from a line normal to the rollingsurface. In some embodiments, the one or more lights is positioned at anangle of greater than or equal to 75 degrees and less than 90 degreesfrom normal as measured from a line normal to the rolling surface. Insome embodiments, the one or more lights is positioned at an angle of 78degrees from normal as measured from a line normal to the rollingsurface. In some embodiments, the one or more lights are positioned asshown in FIGS. 1-6.

In some embodiments, the plate is positioned between the prism and thesurface of the roll. In some embodiments, the plate includes one or moreapertures 160 (860) to allow the light source to illuminate the rollsurface and provide the camera a view the surface of the roll. In someembodiments, the angle of the side wall of the aperture relative to aline normal to plate is 30 degrees. In some embodiments, the angle ofthe side wall of the aperture relative to a line normal to plate is 40degrees. In some embodiments, the angle of the side wall of the aperturerelative to a line normal to plate is 15 degrees. In some embodiments,the angle of the side wall of the aperture relative to a line normal toplate is 45 degrees. In some embodiments, the angle of the side wall ofthe aperture relative to a line normal to plate is 60 degrees.

In some embodiments, the one or more apertures is at least partiallyfilled with coolant. In some embodiments, the one or more apertures isfilled with coolant. In some embodiments, the one or more apertures isfilled with fluid from a source other than the coolant. In someembodiments, the fluid used to at least partially fill the one or moreapertures is different than the coolant used to remove heat generatedfrom grinding. In some embodiments, the fluid used to at least partiallyfill the one or more apertures and the coolant used to remove the heatgenerated from grinding are supplied via separate feed lines, spouts,nozzle, and/or distribution valves.

In some embodiments, the coolant may be diluted using a water supplybefore use as fluid to at least partially fill the at least oneapertures. In some embodiments, the coolant and/or the fluid used to atleast partially fill the at least one apertures may include water and atleast one surface configured to reduce or eliminate rust buildup on theroll surface.

In some embodiments, the plate provides flow control of the coolant bycreate a seal with the roll surface. In some embodiments, the coolantflows through the aperture of the plate and then exits through one ormore holes in the plate. In some embodiments, the plate does not contactthe rolling surface.

In some embodiments, the plate is formed of plastic. In someembodiments, the plate is formed of glass. In some embodiments, theplate is formed of a polymeric material. In some embodiments, the plateis either transparent or translucent. FIG. 8A shows a top view of anon-limiting example of the plate of the present invention. FIGS. 8B and8C show cross-sectional views of a non-limiting example of the plate ofthe present invention.

In some embodiments, the distance between the plate and the roll isgreater than 0 and less than 1 inch. In some embodiments, the distancebetween the plate and the roll is greater than 0 and less than 0.1 inch.In some embodiments, the distance between the plate and the roll isgreater than 0 and less than 0.05 inch. In some embodiments, thedistance between the plate and the roll is 0.005 inch.

In some embodiments, the camera, light source, prism, and/or plate aremounted on a device configured to reduce the variation in the distancebetween the plate and the roll. In some embodiments, the mounting deviceis a linear slide capable of manual or automatic adjustment.

In some embodiments, a sensor is used to automatically control thedistance between the plate and the roll. In some embodiments, the sensorautomatically maintains the distance between the plate and the rollbetween 0 and 0.020 inch. In some embodiments, the sensor automaticallymaintains the distance between the plate and the roll between 0 and0.005 inch. In some embodiments, the sensor automatically maintains thedistance between the plate and the roll at 0.005 inch.

In some embodiments, the flow rate of the coolant is controlled using aflow control valve or equivalent. In some embodiments, the flow rate ofthe coolant is controlled so as to remove heat generated by the grindingprocess while maintaining a sufficient temperature of the grinding wheelto allow for self-sharpening. In some embodiments, the flow rate of thecoolant ranges from 1 gallons per minute (gpm) to 2 gpm. In someembodiments, the flow rate of the coolant ranges from 1 gpm to 3 gpm. Insome embodiments, the flow rate of the coolant ranges from 1 gpm to 5gpm. In some embodiments, the flow rate of the coolant ranges from 1 gpmto 7 gpm. In some embodiments, the flow rate of the coolant ranges from1 gpm to 10 gpm.

In some embodiments, the method includes continuous in-process imagingof a surface of a roll. In some embodiments, the imaging is conductedduring the grinding process. In some embodiments, the light sourceprovides light for illuminating the roll. In some embodiments, the lightis refracted using a prism positioned between the light source and aroll. In some embodiments, an image of the surface of the roll isreceived by a camera that includes at least one row of pixel sensors. Insome embodiments, at least one frame produced by the camera is receivedby a computer system. In some embodiments, the computer system providesa two dimensional image of the roll face based, at least in part, on theat least one frame provided by the camera.

A non-limiting example of a frame from the camera is shown in FIG. 9. Inthe non-limiting example, the frame shown in FIG. 9 is provided by aline scan camera. In the non-limiting example, the lines are provided bythe camera at a speed ranging from about 1000-5000 lines per secondbased on the speed of the roll as the roll rotates under the view of thecamera. In some embodiments the speed ranges from about 1000-10000 linesper second. In some embodiments the speed ranges from about 500-5000lines per second. In some embodiments the speed ranges from about100-5000 lines per second. In some embodiments the speed ranges fromabout 1000-4000 lines per second. In some embodiments the speed rangesfrom about 1000-3000 lines per second. In some embodiments the speedranges from about 100-2000 lines per second. In some embodiments thespeed ranges from about 1000-2000 lines per second. In some embodimentsthe speed is greater than 5000 lines per second. In some embodiments thespeed is less 100 lines per second.

In some embodiments, the lines are accumulated to form a “frame”. Insome embodiments, the frame is formed from about 1000 lines per framebased, at least in part, on the size of the visual device used to viewthe frame. In some embodiments, the frames are provided at a speedranging from about 1 to 5 frames per second. In some embodiments, theframes are provided at a speed ranging from about 1 to 10 frames persecond. In some embodiments, the frames are provided at a speed rangingfrom about 2 to 3 frames per second. In some embodiments, the frames areprovided at a speed ranging from about 1 to 7 frames per second. In someembodiments, the frames are provided at a speed ranging from about 1 to3 frames per second. In some embodiments, the frames are provided at aspeed greater than 10 frames per second. In some embodiments, the framesare provided at a speed less than 10 frames per second.

In the non-limiting example, the frame shown in FIG. 9 covers about 1inch in the transverse direction (along the length of the roll) andabout 10 inches in the circumferential direction. In the non-limitingexample, lighting positioned at an angle of greater than 75 degreescauses most of the roll surface to appear dark in the frame shown inFIG. 9. In the non-limiting example, deep scratches on the surfaceappear as bright spots on the frame in FIG. 9.

In some embodiments, the frames may be combined together to form animage. In some embodiments, the number of frames ranges from 100 to 1000frames. In some embodiments, the number of frames ranges from 300 to 900frames. In some embodiments, the number of frames ranges from 600 to 800frames. In some embodiments, the number of frames is 700 frames.

In some embodiments, the system and method combine the frames based, atleast in part, on the rotational speed of the roll and the speed of thecamera traversing the roll face. In some embodiments, the system andmethod deletes the frames and/or sections of frames that are duplicativeof other frames and/or sections of frames. In some embodiments, thecamera may traverse 0.1 inch of the roll for each revolution of the rollwhile the camera provides frames that are greater than 0.1 inch. In someembodiments, the portions of the frame that are greater than 0.1 inchare deleted during the frame combination step.

In some embodiments, the system and method use the speed of the roll andthe speed of the camera traversing the roll to combine the frames intoan accurate image. In some embodiments, the image may be about 5000pixels high by about 100,000 pixels wide. In some embodiments, the imagemay be about 1000 pixels high by about 50,000 pixels wide. In someembodiments, the image may be about 2000 pixels high by about 100,000pixels wide. In some embodiments, the image may be about 5000 pixelshigh by about 50,000 pixels wide. In some embodiments, the image may beabout 10,000 pixels high by about 100,000 pixels wide. In someembodiments, the image may be about 20,000 pixels high by about 50,000pixels wide.

In some embodiments, the system and method generate an image of the rollsurface via independent control of the image resolution in thetransverse and circumferential directions. In some embodiments, theresolution of the image in the transverse direction may be finer thanthe resolution in the circumferential direction. In some embodiments,the resolution of the image may be about 0.001 inch per pixel in thetransverse direction compared with the resolution of the image in thecircumferential direction of about 0.010 inch per pixel. In someembodiments, the resolution of the image may be about 0.01 inch perpixel in the transverse direction compared with the resolution of theimage in the circumferential direction of about 0.1 inch per pixel. Insome embodiments, the resolution of the image may be about 0.001 inchper pixel in the transverse direction compared with the resolution ofthe image in the circumferential direction of about 0.10 inch per pixel.In some embodiments, the resolution of the image may be about 0.1 inchper pixel in the transverse direction compared with the resolution ofthe image in the circumferential direction of about 0.1 inch per pixel.

In some embodiments, the system and method uses this variation inresolution in the transverse and circumferential directions to highlightdefects in the roll surface.

In a non-limiting example, the image in FIG. 10 was further modified toreduce resolution by a factor of 60 in the transverse direction and afactor of 6 in the circumferential direction to show a defect in theroll surface called a “pattern”. In some embodiments, the system andmethod uses other modifications to the resolution in the transverseand/or circumferential directions to modify the image and/or identifyother defects in a roll surface. In other embodiments, the system andmethod may use full resolution to identify defects in the roll surface.

A non-limiting example of a two dimensional image of a roll is shown inFIG. 10. In the non-limiting example, the image of FIG. 10 is generatedusing a computer system to process about 700 frames that were collectedfrom the camera while the roll rotated and the camera traversed the rollface. In the non-limiting example, the roll surface is “unwrapped” toform a two dimensional image. In the non-limiting example, the lines andpatterns on the two dimensional image indicate defects that requireadditional evaluation.

In some embodiments, the evaluation of the defects identified on the twodimensional image generated by the computer system is conductedmanually. In some embodiments, the roll is subjected to additionalgrinding based at least in part on the manual evaluation of the defectsidentified on the two dimensional image generated by the computersystem. In some embodiments, the evaluation of the defects identified onthe two dimensional image generated by the computer system is conductedautomatically. In some embodiments, the roll is subjected to additionalgrinding based at least in part on the automatic evaluation of thedefects identified on the two dimensional image generated by thecomputer system. In some embodiments, the grinding process iscontinuously adjusted based, at least in part, by the automaticevaluation of the defects identified on the two dimensional imagegenerated by the computer system.

Illustrative Operating Environments

FIG. 11 illustrates one embodiment of an environment in which thepresent invention may operate. However, not all of these components maybe required to practice the invention, and variations in the arrangementand type of the components may be made without departing from the spiritor scope of the present invention. In some embodiments, the system andmethod may include a large number of members and/or concurrenttransactions. In other embodiments, the system and method are based on ascalable computer and network architecture that incorporates variesstrategies for assessing the data, caching, searching, and databaseconnection pooling. An example of the scalable architecture is anarchitecture that is capable of operating multiple servers.

In embodiments, members of the computer system 702-704 include virtuallyany computing device capable of receiving and sending a message over anetwork, such as network 705, to and from another computing device, suchas servers 706 and 707, each other, and the like. In embodiments, theset of such devices includes devices that typically connect using awired communications medium such as personal computers, multiprocessorsystems, microprocessor-based or programmable consumer electronics,network PCs, and the like. In embodiments, the set of such devices alsoincludes devices that typically connect using a wireless communicationsmedium such as cell phones, smart phones, pagers, walkie talkies, radiofrequency (RF) devices, infrared (IR) devices, CBs, integrated devicescombining one or more of the preceding devices, or virtually any mobiledevice, and the like. Similarly, in embodiments, client devices 702-704are any device that is capable of connecting using a wired or wirelesscommunication medium such as a PDA, POCKET PC, wearable computer, andany other device that is equipped to communicate over a wired and/orwireless communication medium.

In embodiments, each member device within member devices 702-704 mayinclude a browser application that is configured to receive and to sendweb pages, and the like. In embodiments, the browser application may beconfigured to receive and display graphics, text, multimedia, and thelike, employing virtually any web based language, including, but notlimited to Standard Generalized Markup Language (SMGL), such asHyperText Markup Language (HTML), a wireless application protocol (WAP),a Handheld Device Markup Language (HDML), such as Wireless MarkupLanguage (WML), WMLScript, XML, JavaScript, and the like. In someembodiments, programming may include either Java, .Net, QT, C, C++ orother suitable programming language.

In embodiments, member devices 702-704 may be further configured toreceive a message from another computing device employing anothermechanism, including, but not limited to email, Short Message Service(SMS), Multimedia Message Service (MIMS), instant messaging (IM),internet relay chat (IRC), mIRC, Jabber, and the like or a Proprietaryprotocol.

In embodiments, network 705 may be configured to couple one computingdevice to another computing device to enable them to communicate. Insome embodiments, network 705 may be enabled to employ any form ofcomputer readable media for communicating information from oneelectronic device to another. Also, in embodiments, network 705 mayinclude a wireless interface, and/or a wired interface, such as theInternet, in addition to local area networks (LANs), wide area networks(WANs), direct connections, such as through a universal serial bus (USB)port, other forms of computer-readable media, or any combinationthereof. In embodiments, on an interconnected set of LANs, includingthose based on differing architectures and protocols, a router may actas a link between LANs, enabling messages to be sent from one toanother.

Also, in some embodiments, communication links within LANs typicallyinclude twisted wire pair or coaxial cable, while communication linksbetween networks may utilize analog telephone lines, full or fractionaldedicated digital lines including T1, T2, T3, and T4, IntegratedServices Digital Networks (ISDNs), Digital Subscriber Lines (DSLs),wireless links including satellite links, or other communications linksknown to those skilled in the art. Furthermore, in some embodiments,remote computers and other related electronic devices could be remotelyconnected to either LANs or WANs via a modem and temporary telephonelink. In essence, in some embodiments, network 705 includes anycommunication method by which information may travel between clientdevices 702-704, and servers 706 and 707.

FIG. 12 shows another exemplary embodiment of the computer and networkarchitecture that supports the method and system. The member devices 802a, 802 b thru 802 n shown each at least includes a computer-readablemedium, such as a random access memory (RAM) 808 coupled to a processor810 or FLASH memory. The processor 810 may execute computer-executableprogram instructions stored in memory 808. Such processors comprise amicroprocessor, an ASIC, and state machines. Such processors comprise,or may be in communication with, media, for example computer-readablemedia, which stores instructions that, when executed by the processor,cause the processor to perform the steps described herein. Embodimentsof computer-readable media may include, but are not limited to, anelectronic, optical, magnetic, or other storage or transmission devicecapable of providing a processor, such as the processor 810 of client802 a, with computer-readable instructions. Other examples of suitablemedia may include, but are not limited to, a floppy disk, CD-ROM, DVD,magnetic disk, memory chip, ROM, RAM, an ASIC, a configured processor,all optical media, all magnetic tape or other magnetic media, or anyother medium from which a computer processor can read instructions.Also, various other forms of computer-readable media may transmit orcarry instructions to a computer, including a router, private or publicnetwork, or other transmission device or channel, both wired andwireless. The instructions may comprise code from anycomputer-programming language, including, for example, C, C++, C#,Visual Basic, Java, Python, Perl, and JavaScript

Member devices 802 a-n may also comprise a number of external orinternal devices such as a mouse, a CD-ROM, DVD, a keyboard, a display,or other input or output devices. Examples of client devices 802 a-n maybe personal computers, digital assistants, personal digital assistants,cellular phones, mobile phones, smart phones, pagers, digital tablets,laptop computers, Internet appliances, and other processor-baseddevices. In general, a client device 802 a are any type ofprocessor-based platform that is connected to a network 806 and thatinteracts with one or more application programs. Client devices 802 a-nmay operate on any operating system capable of supporting a browser orbrowser-enabled application, such as Microsoft™, Windows™, or Linux. Theclient devices 802 a-n shown may include, for example, personalcomputers executing a browser application program such as MicrosoftCorporation's Internet Explorer™, Apple Computer, Inc.'s Safari™,Mozilla Firefox, and Opera. Through the client devices 802 a-n, users,812 a-n communicate over the network 806 with each other and with othersystems and devices coupled to the network 806. As shown in FIG. 12,server devices 804 and 813 may be also coupled to the network 806.

In some embodiments, the term “mobile electronic device” may refer toany portable electronic device that may or may not be enabled withlocation tracking functionality. For example, a mobile electronic devicecan include, but is not limited to, a mobile phone, Personal DigitalAssistant (PDA), Blackberry™, Pager, Smartphone, or any other reasonablemobile electronic device. For ease, at times the above variations arenot listed or are only partially listed, this is in no way meant to be alimitation.

In some embodiments, the terms “proximity detection,” “locating,”“location data,” “location information,” and “location tracking” as usedherein may refer to any form of location tracking technology or locatingmethod that can be used to provide a location of a mobile electronicdevice, such as, but not limited to, at least one of locationinformation manually input by a user, such as, but not limited toentering the city, town, municipality, zip code, area code, crossstreets, or by any other reasonable entry to determine a geographicalarea; Global Positions Systems (GPS); GPS accessed using Bluetooth™; GPSaccessed using any reasonable form of wireless and/or non-wirelesscommunication; WiFi™ server location data; Bluetooth™ based locationdata; triangulation such as, but not limited to, network basedtriangulation, WiFi™ server information based triangulation, Bluetooth™server information based triangulation; Cell Identification basedtriangulation, Enhanced Cell Identification based triangulation,Uplink-Time difference of arrival (U-TDOA) based triangulation, Time ofarrival (TOA) based triangulation, Angle of arrival (AOA) basedtriangulation; techniques and systems using a geographic coordinatesystem such as, but not limited to, longitudinal and latitudinal based,geodesic height based, cartesian coordinates based; Radio FrequencyIdentification such as, but not limited to, Long range RFID, Short rangeRFID; using any form of RFID tag such as, but not limited to active RFIDtags, passive RFID tags, battery assisted passive RFID tags; or anyother reasonable way to determine location. For ease, at times the abovevariations are not listed or are only partially listed, this is in noway meant to be a limitation.

In some embodiments, near-field wireless communication (NFC) canrepresent a short-range wireless communications technology in whichNFC-enabled devices are “swiped,” “bumped,” “tap” or otherwise moved inclose proximity to communicate. In some embodiments, NFC could include aset of short-range wireless technologies, typically requiring a distanceof 10 cm or less.

In some embodiments, NFC may operate at 13.56 MHz on ISO/IEC 18000-3 airinterface and at rates ranging from 106 kbit/s to 424 kbit/s. In someembodiments, NFC can involve an initiator and a target; the initiatoractively generates an RF field that can power a passive target. In someembodiment, this can enable NFC targets to take very simple form factorssuch as tags, stickers, key fobs, or cards that do not requirebatteries. In some embodiments, NFC peer-to-peer communication can beconducted when a plurality of NFC-enable devices within close proximityof each other.

While a number of embodiments of the present invention have beendescribed, it is understood that these embodiments are illustrativeonly, and not restrictive, and that many modifications may becomeapparent to those of ordinary skill in the art. Further still, thevarious steps may be carried out in any desired order (and any desiredsteps may be added and/or any desired steps may be eliminated)

1. A method comprising: lighting a surface of a roll using a lightsource and a prism; wherein the light source and the prism arepositioned to provide light to the surface of the roll at an angle of atleast 75 degrees as measured from a line normal to the surface of theroll; receiving, by at least one specifically programmed computersystem, a plurality of lines from a line scan camera while the roll isrotating; wherein each line corresponds to a section of the roll;creating, by the at least one specifically programmed computer system, aplurality of frames based, at least in part, on the plurality of lines;generating, by the at least one specifically programmed computer system,the two-dimensional image of the surface of the roll based, at least inpart, on the plurality of frames.
 2. The method of claim 1, wherein theplurality of lines is received at a speed of 1000 to 5000 lines persecond.
 3. The method of claim 1, wherein each of the plurality offrames is formed of at least 1000 lines.
 4. The method of claim 1,wherein the surface of the roll is at least partially covered by a fluidduring the receiving step.
 5. The method of claim 1, wherein the linescan camera moves in a transverse direction relative to the roll duringthe receiving step.
 6. The method of claim 5, wherein a first speed ofthe rotating roll is greater than a second speed of the moving line scancamera.
 7. The method of claim 1, wherein the first resolution of theimage in the transverse direction is less than a second resolution ofthe image in a circumferential direction.
 8. A method comprising:lighting a surface of a roll using a light source and a prism; whereinthe light source and the prism are positioned to provide light to thesurface of the roll at an angle of at least 75 degrees as measured froma line normal to the surface of the roll; receiving, by at least onespecifically programmed computer system, a plurality of lines from aline scan camera while the roll is rotating; wherein each linecorresponds to a section of the roll; creating, by the at least onespecifically programmed computer system, a plurality of frames based, atleast in part, on the plurality of lines; generating, by the at leastone specifically programmed computer system, the two-dimensional imageof the surface of the roll based, at least in part, on the plurality offrames; evaluating, by the at least one specifically programmed computersystem, defects on the roll based, at least in part, on thetwo-dimensional image of the surface of the roll; and grinding the rollbased, at least in part, on the evaluation of the defects on the roll.9. The method of claim 8, wherein the evaluating step and the generatingstep are conducted concomitantly.
 10. The method of claim 8, wherein theevaluating step and the grinding step are conducted concomitantly. 11.The method of claim 8, wherein the surface of the roll is at leastpartially covered by a fluid during the receiving step.
 12. The methodof claim 15, wherein the line scan camera moves in a transversedirection relative to the roll during the receiving step.